Keywords

structural batteries; aerospace; composite materials; energy storage; carbon fiber; zinc-ion batteries

Abstract

There is increasing pressure on the aviation sector to lower carbon emissions and switch to entirely electric and hybrid propulsion systems. However, the feasibility of standard lithium-ion batteries for long-range aircraft is limited, as they add substantial weight and occupy significant volume. Structural batteries, which combine load-bearing capability with energy storage, offer a potential pathway to lighter and more efficient aerospace systems.

This work investigates a carbon-fiber-based structural battery that utilizes carbon fiber as both a current-collecting, load-bearing electrode and a component of the composite structure. In contrast to lithium-ion chemistries, a zinc-based aqueous electrolyte is chosen for better environmental compatibility and safety. A zinc-plated carbon-fiber anode completes the cell, while conductive additives, polymer binders, and cathode material based on Prussian Blue Analogue are included in a carbon-fiber laminate. This thesis focuses on material selection, electrode preparation, and assembly methods for early-stage structural battery laminates.

Galvanostatic charge and discharge cycle electrochemical testing demonstrates consistent voltage profiles, confirming the composite architecture's capacity to store energy while maintaining structural integrity. These results establish a foundation for future work that will quantify dual-functional performance through mechanical testing and extended electrochemical cycling. In the long term, the concepts developed here are intended to support the integration of structural batteries into aircraft components and related applications, such as lightweight prosthetics and humanized robotic systems.

Thesis Completion Year

2026

Thesis Completion Semester

Spring

Thesis Chair

Thomas, Jayan

College

College of Engineering and Computer Science

Department

Mechanical and Aerospace Engineering

Thesis Discipline

Aerospace Engineering

Language

English

Access Status

Open Access

Length of Campus Access

None

Campus Location

Orlando (Main) Campus

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